Based on the extent of the rust around the area on the floor which the sills attach to and a lot of the perimeter sections I decided the best approach would be to replace the floor entirely (this will give me a chance to clean up most of the underside properly and restore it fully).
Starting to chop the floor out in sections:
Front half out:
Nearly there:
All that I could find of the offside middle sill:
And majority of the floor out, just the areas around the edges left to unpick from the walls (just to think 4 months ago I was driving this around as my only vehicle!):
Having assessed the cross floor supports it looks like I’ll need to do the following:
- 1st support – Already taken out, new one to fit.
- 2nd and 3rd I beam supports – In fairly good nick so I’ll repair the sections that need repairing.
- 4th tophat – Minor repairs.
- 5th and 6th tophat – Given that these are only welded to the chassis legs now and need some significant repair I think I’ll just replace both of them to save time.
